Overseas cap and method of making same



July 30, 1963 v G. B. WAGENFELD 3,394,409

OVERSEAS CAP AND METHOD OF MAKING SAME Filed Feb. 14, 1966 3 Sheets-Sheet l awe/wax? GDLBERT 5. WHGENF LD Julyv 30, 1968 G. B. WAGENFELD 3,394,409

OVERSBAS CAP AND METHOD OF MAKING SAME Filed Feb. 14, 19 6 3 Sheets-Sheet 2 uwz-wmw (ALBERT B. WHGENFELD y 30, 1968 G. a. NAGENFELD 3,394,409

OVERSEAS CAP AND METHOD OF MAKING SAME Filed Feb. 14, 1966 3 $heets-Sheet 5 //VI/E/V7'0/? GILBERT WHGEN FELD United States Patent 3,394,409 OVERSEAS CAP AND METHOD OF MAKING SAME Gilbert B. Wagenfeld, Bala Cynwyd, Pa., assignor to Cellucap Manufacturing Co., Philadelphia, Pa., a corporation of Pennsylvania Filed Feb. 14, 1966, Ser. No. 527,377 9 Claims. (Cl. 2195) ABSTRACT OF THE DISCLOSURE This invention relates generally to headwear, and more particularly relates to that type of headwear which simulates in general appearance the well known military overseas cap.

A principal object of the present invention is to provide a cap of the aforementioned type which is simple in design and construction and comparatively simple and inexpensive to manufacture.

Another object of the present invention is to provide a cap as aforesaid in which the crown portion of the cap is free of the headband side panels for substantially the full perimeter of the hat and is secured to the headband at the lower margin thereof to permit free movement of the crown with respect to the cap side panels thereby resulting in better conformity of the crown portion to the head of the wearer.

A further object of this invention is to provide a novel and inexpensive method for the fabrication of caps according to the invention, which method is capable of high speed production to thereby reduce the unit cost of caps so produced.

The foregoing and other objects of my invention will become clear from a reading of the following specification in conjunction with an examination of the appended drawings, wherein:

FIGURE 1 is a perspective view of an assembled cap according to the invention;

FIGURE 2 is a perspective view of a portion of a continuous web of material from which the crown portion of the cap is fabricated;

FIGURE 3 is a perspective view of a portion of a continuous web of material from which the cap headband portion is formed;

FIGURES 4, 6 through 9 and 11 show successive steps in the method of forming the overseas caps from the webs of material shown in FIGURES 2 and 3;

FIGURE is an enlarged vertical section taken through the structure of FIGURE 4 as would be seen when viewed along line 5-5 thereof;

FIGURE is an enlarged fragmentary vertical section taken through the substantially completed cap structures as would be seen when viewed along the line 1010 of FIGURE 9;

FIGURE 12 is an enlarged vertical sectional view taken through a pair of completed and symmetrically formed caps according to the invention as would be seen when viewed along the line 1212 of FIGURE 11; and FIGURE 13 is an enlarged vertical sectional view 3,394,4fi9 Patented July 30, 1968 taken through the expanded out and completed overseas cap according to the invention as would be seen when viewed along the line 13-13 of FIGURE 1.

In the several figures, like elements are denoted by like reference characters.

Turning now to a consideration of the figures, in FIG- URE 1 there is seen a perspective view of the cap according to the invention which has a crown portion designated generally as 20 and a headband portion designated generally as 21, the crown and headband portions being cemented together at their bottom edges in a manner not visible in FIGURE 1. A clearer understanding of the structural configuration of the cap is most readily accomplished by tracing fabrication of the cap from the two webs of material from which the crown and headband portions of the cap are fabricated, these webs being shown in FIGURES 2 and 3 and designated respectively as crown forming web 22 and headband forming web 23.

The crown forming web 22 is a continuous running length of constant width material such as crepe paper or crinoline having its longitudinally extending side edges turned upward and inward into overlying relationship with respect to the main part of the web to form crown top margins 24 at opposite edges of the web 22. The width of the web 22 with the side margins turned inward is equal to twice the height of the crown portion of a finished cap, and in fact as will be subsequently seen, two complete caps will be formed from the web width.

The headband forming web 23 is substantially narrower than the web 22 and in a typical case would be approximately one half the width of web 22, the headband forming web 23 being made of a light cardboard material to impart suflicient shape holding stiifness to the finished cap while allowing for relatively resilient deformation. The headband forming web 23 is provided with a continuous longitudinally centrally extending adhesive stripe 25 disposed continuously on opposite sides of the broken line 26 which designates the center of the web 23 and along which the web 23 will be subsequently cut to simultaneously complete the formation of two caps. The adhesive 25 on each side of line 26 lies along a narrow margin of what in the finished cap is the lower edge of the headband.

Also shown on the web 23 are broken lines 27a and 28a extending transversely to the web at right angles to the center line 26 and longitudinally spaced apart a distance slightly in excess of twice the front to back length of a finished cap, these broken lines 27a and 25a representing lines of severance to be subsequently made which will sever from the web a length of material from which two caps will ultimately be formed. Corresponding to the lines 27a and 28a of the headband forming web 23 are lines 27b and 23b designated on the crown forming web 22 shown in FIGURE 2, the separation of lines 2717 and 281) being the same as that of 27a and 28a.

Adhesive stripes 29 are laid down transversely on the web 23 orthogonal to the centrally extending adhesive stripe 25 and longitudinally spaced apart so that the center of the adhesive stripes 29 coincide with the locations of the broken lines 27a and 2801. It will of course be appreciated that in actual practice it is not necessary to actually have physically printed upon the web 23 any of the broken lines 26, 27a or 28a, and similarly the broken lines 27b and 28b as shown on web 22 are not required. These broken lines are shown in the drawings merely for purposes of description to clarify the dimensional relationships and corresponding parts in different ones of the figures.

The webs 22 and 23 as shown in FIGURES 2 and 3 are fed into combining or laminating machinery, such devices being well known in the paper fabrication arts,

and adhered together along their running length with their longitudinal center lines in coincidence as shown in FIG- URE 4, the upper surface of web 23 and the undersurface of web 22 being bonded together throughout the regions of the adhesive stripes 25 and 29. The laminated webs are next transversely scored along lines 30 and 31 as shown in FIGURE 6, and are then transversely out along the previously designated broken lines 27a-27b and 28a28b, alson seen in FIGURE 6.

Next, the crown portion margins 24 have applied thereto throughout their length an adhesive 32, and the laminated webs to the right of score lines 30 are turned about score line 30 so that the adhesively coated crown margins 24 of that part of the laminate are brought into fiat faced engagement with the portions of the crown margins 24 which lie between the score lines and 31 to thereby strongly adhere these crown margins portions to one another. As best seen in FIGURE 7, this last fabrication step causes the edges 2811-28b of the laminate to directly overlie score line 31.

As best seen in FIGURES 6 and 7, extending freely beyond score line 31 to the proximate edge 27a27b of the laminate is a narrow rear end flap 33 which, as shown in FIGURE 8, is now coated with a layer of adhesive 34. Adhesively coated end flaps 33, a seen in FIGURE 9, is next turned backward about score line 31 enclosing laminate edge 280-2811 and being adhesively secured downward upon the marginal edge of the laminate immediately adjacent to the enclosed edge. As shown in FIGURE ll, the adhesively secured laminated structure is cut longitudinally centrally along a line corresponding to the position of broken line 26 shown in FIG- URE 3 to thereby form two complete caps each with two cap sides of equal length and height.

It will of course be appreciated that the order of carrying out certain of the steps of fabricating the caps is not critical and could in some instances be altered. For example, it is not mandatory that the crown top margins 24 of crown portion web 22 be turned over proior to lamination of web 22 with web 23. Similarly, it is not necessarily required that the score lines 30 and 31 be applied prior to cutting to length of the laminate, it being possible in some cases to cut and then score while in other cases it may be desirable to simultaneously score and cut. Other sequence variations may of course suggest themselves in particular applications.

Understanding now the method of fabricating the novel overseas cap according to the invention, it is clear from the vertical sectional view of FIGURE 13 that the crown portion 20 formed from web 22 is secured peripherally by the adhesive to the bottom edge of the headband portion 21 formed from the web 23, the crown being otherwise unsecured to the side panels except at the rear edge fold line 31 where the crown and side panel are vertically adhesively secured. As a consequence of this construction it will be now appreciated that the crown portion 20 is substantially free of the restraint usually imposed by the side panels of the headband 21 in the ucual constructions of this type so that the crown may readily take a conforming shape to the head of the wearer. Further, it should be noted that there is no waste material whatever, that there are only two double ply thickness regions in the entire cap, namely at the rear vertical fold and along the top edge of the crown to thereby effect great savings in material, and that two entire caps are formed with merely two cuts effected in two cutting operations and four folds effected in three folding operations.

Having now described my invention in connection with a particularly illustrated embodiment thereof, modifications and variations of my invention may now occur from time to time to those persons normally skillled in the art without departing from the essential scope Or spirit of the invention, and accordingly it is intended to claim the same broadly as well as specifically as indicated by the appended claims.

What is claimed to be new and useful is:

1. A paper cap having front and rear edges and comprising in combination, a headband having an upper edge and a lower edge, and a crown portion adhesively secured flatwise to said headband lower edge, said headband having side panels and comprising a single elongated rectangular piece of relatively stiff but flexible paper stock having long edges and opposite end margins, said long edges being slightly longer than twice the front to back length of the cap when the latter is in flat folded form and said end margins being of a width equal to the desired height of the headband side panels, said crown portion having a top closure and comprising a single elongated rectangular piece of flexible material having long edges of the same length as the piece of handband stock and end margins of a wider width thereof suflicient so that the desired crown height in the finished cap includes an edge of the crown material coincident with a narrow margin of the long edge of the headband stock which in the finished cap is the lower edge of the headband, said pieces of headband stock and crown material being also positioned lengthwise coextensively with the opposite end margins of said headband stock adhesively secured to the facing end margins of said crown material so that they comprise a laminate of headband stock and crown material, said laminate having a transverse widthwise fold along a first line near one end thereof and a transverse widthwise fold along a second line midway between the first line and the remote end of the laminate so that said cap has two cap sides of equal length and height and an end flap, said cap sides being disposed fiatwise against one another so that the headband piece is on the outside and said second fold line forms the front edge of the cap, the end flap being adhesively secured widthwise against the opposite end of the laminate to form the cap rear edge, and the long edge of the crown material not secured to the headband piece and forming the front to back extending upper edge of the crown being adhesively secured together and comprising the crown top closure.

2. The paper cap as described in claim 1 wherein the said end flap adhesively secured widthwise against the marginal edge of the opposite end of the laminate is secured against the outer face of such marginal edge to thereby overlie the same with the end of the laminate disposed substantially at the said first fold line within the fold.

3. The paper cap as described in claim 1 wherein the said front to back extending adhesively secured upper edge of the crown comprises a pair of down-turned longitudinally front to back extending crown material margins in face to face adhesively secured contact.

4. A paper cap comprising in combination a headband and a crown portion, said headband comprising a flattened tube of light cardboard having front and rear folded edges, said tube being of fixed perimetr-al extent open at both ends and of height between the open ends less than the width of the flattened tube between said front and rear edges, said crown portion comprising a flat rectangular one piece envelope of fixed perimetral extent having two closed short opposite ends and one closed and one open long edge, the length of said crown forming envelope between the closed short end being minimally shorter than the length of said flattened tube between the said front and rear edges of the latter and thereby providing close fitting disposition of the envelope within said flattened tube with the outside surface of the envelope in contact with the inside surface of the tube and with a narrow peripheral margin at the open edge of the envelope being coincident with and continuously peripherally sealed to a narrow peripheral margin on the inside surface of the tube immediately adjacent to the end of the tube which forms the open bottom of the cap.

5. A paper cap as described in claim 4 wherein said crown portion closed short opposite ends are disposed respectively in the front and rear folds of the flattened tube forming said headband, and one of said crown portion closed ends is secured to the headband in its associated fold, the crown and headband being otherwise free of intersecurement.

6. A method of continuously making caps having intersecured separate headband and crown portions consisting of the steps of,

(a) turning inward the opposite longitudinally extending side edges of a continuous web of constant width crown portion forming material to form crown web narrow side margins,

(b) applying a continuous stripe of adhesive longitudinally centrally to a continuous web of headband forming material and applying stripes of adhesive transversely to said headband web at longitudinally equispaced intervals therealong such that the transversely extending center lines of each adjacent pair of such transverse stripes are spaced apart somewhat in excess of twice the front-to-back length of the cap to be formed,

(c) positioning and pressing together the crown Web and headband web so that their longitudinal center lines are coincidental and the two webs are adhesively secured by the aforesaid adhesive stripes to form a laminate in which the crown Web surface which engages the head of the wearer is free of attachment to the headband Web,

(d) transversely cutting through the laminate along the center line of each transverse adhesive stripe to sever successive equal lengths of the laminate, and transversely scoring each such laminate length proximate to one severed end thereof to form an end flap and also transversely scoring midway between the first mentioned score and the severed end of the laminate length remote therefrom to form a pair of identical panels disposed one on each side of said second mentioned score,

(e) adhesively coating said crown Web side margins and folding said laminate about said second score line to overlay one of said pair of identical panels with the other and adhesively secure together the overlaid lengths of each web side margin,

(f) adhesively coating said end flap and turning it over onto and adhesively securing it to the marginal edge of the laminate originally remote from the end flap, and

(g) longitudinally cutting through the folded and adhesively secured laminate along the coincident longitudial center lines of the crown and headband web parts forming the laminate to sever the latter into two finished caps.

7. The method of making caps as set forth in claim 6, wherein the steps of applying tnansverse stripes of adhesive to the headband web are carried on for a time sulficient to produce continuous stripes for the full width of the headband Web.

8. The method of making caps as set forth in claim 6 wherein the steps of app-lying said transverse adhesive stripes and said steps of transverse cuttings and scorings are all carried out orthogonally t0 the longitudinal center lines of said webs.

9. The method of making caps as set forth in claim 6 wherein, the steps of applying transverse stripes of adhesive to the headband web are carried on for a time sufficient to produce continuous stripes for the full width of the headband web, and the steps of applying said transverse adhesive stripes and said steps of transverse cuttings and scorings are all carried out orthogonally to the longitudinal center lines of said webs.

References Cited UNITED STATES PATENTS 1,806,225 5/ 1931 Vernon 2-200 2,682,668 7/1954 Hoepl-ich 2-200 X 2,990,552 7/1961 De Villers 2195 3,082,430 3/ 1963 Wagenfeld 2-197 JORDAN FRANKLIN, Primary Examiner.

G. H. KRIZMANICH, Assistant Examiner. 

